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1. WO2020113334 - COMPOSITES ÉLASTOMÈRES ET SES PROCÉDÉS DE FABRICATION

Note: Texte fondé sur des processus automatiques de reconnaissance optique de caractères. Seule la version PDF a une valeur juridique

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CLAIMS:

1 . A syntactic elastomeric composite comprising an elastomer and a plurality of insoluble particles embedded therein, wherein the insoluble particles have at least one of compressive yield point, decomposition temperature point, melting point and density lower than at least one of compressive yield point, decomposition temperature point, melting point and density of the elastomer.

2. An elastomeric composite comprising an elastomer and a plurality of insoluble particles embedded therein, wherein the insoluble particles have at least one of compressive yield point, decomposition temperature point, melting point and density lower than at least one of compressive yield point, decomposition temperature point, melting point and density of the elastomer.

3. The composite of claim 1 or 2, wherein the mixture comprises about 50 wt. % to about 99 wt. % of the elastomer.

4. The composite of claim 1 or 2, wherein the mixture comprises about 60 wt. % to about 99 wt. % of the elastomer.

5. The composite of claim 1 or 2, wherein the mixture comprises about 70 wt. % to about 99 wt. % of the elastomer.

6. The composite of claim 1 or 2, wherein the mixture comprises about 80 wt. % to about 99 wt. % of the elastomer.

7. The composite of claim 1 or 2, wherein the mixture comprises about 90 wt. % to about 99 wt. % of the elastomer.

8. The composite of any one of claims 1 to 7, wherein the mixture comprises about 1 wt. % to about 40 wt. % of the insoluble particles.

9. The composite of any one of claims 1 to 7, wherein the mixture comprises about 1 wt. % to about 30 wt. % of the insoluble particles.

10. The composite of any one of claims 1 to 7, wherein the mixture comprises about 1 wt. % to about 20 wt. % of the insoluble particles.

11. The composite of any one of claims 1 to 7, wherein the mixture comprises about 1 wt. % to about 15 wt. % of the insoluble particles.

12. The composite of any one of claims 1 to 7, wherein the mixture comprises about 1 wt. % to about 10 wt. % of the insoluble particles.

13. The composite of any one of claims 1 to 7, wherein the mixture comprises about 1 wt. % to about 5 wt. % of the insoluble particles.

14. The composite of any one of claims 1 to 13, wherein the insoluble particles are chosen from chemical particles, optionally polymers, and natural particles, optionally wood.

15. The composite of any one of claims 1 to 14, wherein the insoluble particles are chosen from expanded polystyrene (EPS), extruded polystyrene (Styrofoam), polypropylene, polyethylene and mixtures thereof.

16. The composite of any one of claims 1 to 15, wherein the insoluble particles are substantially spherical.

17. The composite of any one of claims 1 to 16, wherein the insoluble particles have an average diameter of about 0.05 mm to about 2 cm.

18. The composite of any one of claims 1 to 16, wherein the insoluble particles have an average diameter of about 0.05 mm to about 0.5 mm.

19. The composite of any one of claims 1 to 18, wherein the size of the insoluble particles is reduced.

20. The composite of any one of claim 1 to 19, wherein the size of the insoluble particles is reduced by applying heat.

21. The composite of any one of claims 1 to 20, wherein the size of the insoluble particles is reduced by applying heat at a temperature of about 130°C to about 200°C.

22. The composite of claim 20 or 21 , wherein the heat is applied for about 30 minutes to about 60 minutes.

23. The composite of any one of claims 1 to 22, wherein the size of the insoluble particles is reduced by applying pressure.

24. The composite of claim 23, wherein about 0.15 MPa to about 0.5 MPa of pressure is applied to the composite.

25. The composite of any one of claims 1 to 24, wherein the composite comprises a plurality of cells having an average size of about 0.05 mm to about 2 cm.

26. The composite of any one of claims 1 to 24, wherein the composite comprises a plurality of cells having an average size of about 0.05 mm to about 0.5 mm.

27. The composite of any one of claims 1 to 18, wherein the insoluble particles are substantially intact.

28. The composite of any one of claims 1 to 27, wherein the composite comprises open cells.

29. The composite of any one of claims 1 to 28, wherein the elastomer is chosen from silicone, vinyl ester, polyester, epoxy, polyurethane, natural rubber, melamine, urea, phenol, formaldehyde resin, and mixtures thereof.

30. The composite of any one of claims 1 to 28, wherein the elastomer is silicone, optionally a one-part or a two-part silicone.

31 . The composite of claim 30, wherein the two-part silicone is a two-part platinum silicone.

32. The composite of any one of claims 1 to 31 , further comprising about 0.1 wt % to about 50 wt. % of a filler chosen from silica, carbon, glass, metal, metal oxide, metal hydroxide, and mixtures thereof.

33. The composite of any one of claims 1 to 32, further comprising about 0.1 wt % to about 50 wt. % of an additive chosen from thixotropes, fire retardants, suppressants, inhibitors, stabilizers, solvents, blowing agents, catalysts, pigments, coloring agents, conductive additives, and mixtures thereof.

34. The composite of claim 33, wherein the additive is a solvent, optionally chosen from ethanol, acetone, toluene and mixtures thereof.

35. The composite of claim 34, wherein the solvent is ethanol.

36. The composite of any one of claims 1 to 35, wherein the insoluble particles are coated.

37. The composite of any one of claims 1 to 35, wherein the insoluble particles are coated with an electrically conductive material, optionally chosen from carbon based fibers, metal based fibers and mixtures thereof.

38. The composite of claim 37, wherein the composite comprises about 0.1 wt. % to about 50 wt. % of the electrically conductive material.

39. The composite of claim 37 or 38, wherein the electrically conductive material is nickel coated carbon fibers.

40. The composite of any one of claims 1 to 39, having a volume resistivity of about 0.1 Ohms to about 1 Megaohm.

41. The composite of any one of claims 1 to 39, having a volume resistivity of about 0.1 Ohms to about 3 Ohms.

42. The composite of any one of claims 1 to 41 , having a density of about 70 kg/m3 to about 700 kg/m3.

43. The composite of any one of claims 1 to 41 , having a density of about 100 kg/m3 to about 500 kg/m3.

44. The composite of any one of claims 1 to 41 , having a density of about 100 kg/m3 to about 400 kg/m3.

45. The composite of any one of claims 1 to 44, having a relative density of about 0.07 to about 0.8.

46. The composite of any one of claims 1 to 44, having a relative density of about 0.1 to about 0.8.

47. The composite of any one of claims 1 to 44, having a relative density of about 0.1 to about 0.5.

48. The composite of any one of claims 1 to 44, having a relative density of about 0.2 to about 0.5.

49. The composite of any one of claims 1 to 44, having a relative density of about 0.2 to about 0.4.

50. The composite of any one of claims 1 to 44, having a relative density of about 0.2 to about 0.35.

51. The composite of any one of claims 1 to 50, wherein the composite is isotropic.

52. The composite of any one of claims 1 to 51 , wherein the composite is viscoelastic.

53. The composite of any one of claims 1 to 52, wherein the composite is viscoelastic-viscoplastic.

54. The composite of any one of claims 1 to 53, wherein the composite comprises at least two integrally connected layers.

55. The composite of claim 54, wherein the at least two integrally connected layers are substantially parallel relative to one another.

56. The composite of claim 54 or 55, wherein the at least two integrally connected layers comprise the same elastomer.

57. The composite of any one of claims 54 to 56, wherein each layer has a different relative density compared to the relative density of an adjacent layer.

58. The composite of any one of claims 54 to 56, wherein each layer has a different average cell size compared to the average cell size of an adjacent layer.

59. The composite of any one of claims 54 to 56, wherein each layer comprises insoluble particles that have a different size, diameter, shape and/or composition, compared to the size, diameter, shape and/or composition of the insoluble particles comprised in an adjacent layer.

60. The composite of any one of claims 1 to 54, wherein the composite comprises three integrally connected layers.

61 . The composite of claim 60, wherein the two outer layers have a relative density greater than the relative density of the middle layer.

62. The composite of claim 60, wherein the two outer layers are integral skins.

63. The composite of any one of claims 1 to 62, comprising a plurality of micropores and a plurality of macropores, optionally wherein the micropores have and average cell size of about 50 microns to about 990 microns and/or the macropores have an average cell size of about 1 mm to about 20 mm.

64. A method of producing a syntactic elastomeric composite, comprising:

preparing a mixture comprising an elastomer, insoluble particles, and optionally a filler and/or an additive, the insoluble particles having at least one of compressive yield point, decomposition temperature point, melting point and density lower than at least one of compressive yield point, decomposition temperature point, melting point and density of the elastomer;

optionally driving the mixture into a cavity;

curing the mixture to obtain the composite; and

optionally reducing the size of the insoluble particles.

65. A method of producing an elastomeric composite, comprising:

preparing a mixture comprising an elastomer, insoluble particles, and optionally a filler and/or an additive, the insoluble particles having at least one of compressive yield point, decomposition temperature point, melting point and density lower than at least one of compressive yield point, decomposition temperature point, melting point and density of the elastomer;

optionally driving the mixture into a cavity;

curing the mixture to obtain the composite; and

optionally reducing the size of the insoluble particles.

66. The method of claim 64 or 65, wherein the mixture is driven prior to the curing.

67. The method of claim 64 or 65, wherein the driven mixture comprises casting, pouring, injecting and/or plunging the mixture into the cavity.

68. The method of any one of claims 64 to 66, wherein the mixture is cured at room temperature.

69. The method of any one of claims 64 to 66, wherein the mixture is cured at a temperature of about 0°C to about 110°C.

70. The method of any one of claims 64 to 66, wherein the mixture is cured at a temperature of about 20°C to about 100°C.

71. The method of any one of claims 64 to 70, further comprising post-curing the composite.

72. The method of any one of claims 64 to 71 , wherein the size of the insoluble particles is reduced by applying heat to the composite.

73. The method of claim 72, wherein the heat is applied at a temperature of about 130°C to about 200°C.

74. The method of claim 72 or 73, wherein the heat is applied for about 30 minutes to about 60 minutes.

75. The method of any one of claims 64 to 74, wherein the size of the insoluble particles is reduced by applying pressure to the composite.

76. The method of claim 75, wherein about 0.15 MPa to about 0.5 MPa of pressure is applied to the composite.

77. The method of claim 75 or76, wherein the pressure is applied to the composite using a calender.

78. The method of claim 75 or 76, wherein the pressure is applied to the composite using an Instron™ universal testing machine.

79. The method of any one of claims 64 to 78, wherein the mixture is prepared using a syringe like device, a vacuum infusion system, a plunger, an injector or an extruder.

80. The method of any one of claims 64 to 79, wherein the insoluble particles are chosen from chemical particles, optionally polymers, and natural particles, optionally wood.

81. The method of any one of claims 64 to 71 , wherein the insoluble particles are chosen from expanded polystyrene (EPS), extruded polystyrene (Styrofoam), polypropylene, polyethylene and mixtures thereof.

82. The method of any one of claims 64 to 81 , wherein the insoluble particles are substantially spherical.

83. The method of any one of claims 64 to 82, wherein the insoluble particles have an average diameter of about 0.05 mm to about 2 cm.

84. The method of any one of claims 64 to 82, wherein the insoluble particles have an average diameter of about 0.05 mm to about 0.5 mm.

85. The method of any one of claims 64 to 84, wherein the composite is porous.

86. The method of any one of claims 64 to 85, wherein the composite comprises a plurality of cells having an average size of about 0.05 mm to about 2 cm.

87. The method of any one of claims 64 to 86, wherein the composite comprises a plurality of cell having an average size of about 0.05 mm to about 0.5 mm.

88. The method of any one of claims 64 to 87, wherein the insoluble particles are substantially intact.

89. The method of any one of claims 64 to 88, wherein the elastomer is chosen from silicone, vinyl ester, polyester, epoxy, polyurethane, natural rubber, melamine, urea, phenol, formaldehyde resins and mixtures thereof.

90. The method of any one of claims 64 to 88, wherein the elastomer is silicone, optionally a one-part or a two-part silicone.

91. The method of claim 90, wherein the two-part silicone is a two-part platinum silicone.

92. The method of any one of claims 64 to 91 , further comprising adding to the mixture a filler chosen from silica, carbon, glass, metal, metal oxide, metal hydroxide and mixtures thereof.

93. The method of any one of claims 64 to 92, further comprising adding to the mixture an additive chosen from thixotropes, fire retardants, suppressants, inhibitors, stabilizers, solvents, blowing agents, catalysts, pigments, coloring agents, conductive additives and mixtures thereof.

94. The method of claim 93, wherein the additive is a solvent, optionally chosen from ethanol, acetone, toluene and mixtures thereof.

95. The method of claim 94, wherein the solvent is ethanol.

96. The method of any one of claims 64 to 95, further comprising adding one or more of a blowing agent, surfactant or additional insoluble particles, optionally hollow or compact insoluble particles, to the mixture.

97. The method of any one of claims 64 to 96, wherein prior to preparing the mixture, the method comprises coating the insoluble particles with an electrically conductive material, optionally chosen from carbon based fibers, metal based fibers and mixtures thereof.

98. The method of claim 97, wherein the electrically conductive material is nickel coated carbon fibers.

99. The method of claim 97 or 98, wherein the composite has a volume resistivity of about 0.1 Ohms to about 1 Megaohm.

100. The method of claim 97 or 98, wherein the composite has a volume resistivity of about 0.1 Ohms to about 3 Ohms.

101. The method of any one of claims 64 to 100, having a density of about 70 kg/m3 to about 700 kg/m3.

102. The method of any one of claims 64 to 100, having a density of about 100 kg/m3 to about 500 kg/m3.

103. The method of any one of claims 64 to 100, having a density of about 100 kg/m3 to about 400 kg/m3.

104. The method of any one of claims 64 to 103, wherein the composite has a relative density of about 0.07 to about 0.8.

105. The method of any one of claims 64 to 104, wherein the composite has a relative density of about 0.1 to about 0.8.

106. The method of any one of claims 64 to 104, wherein the composite has a relative density of about 0.1 to about 0.5.

107. The method of any one of claims 64 to 104, wherein the composite has a relative density of about 0.2 to about 0.5.

108. The method of any one of claims 64 to 104, wherein the composite has a relative density of about 0.2 to about 0.4.

109. The method of any one of claims 64 to 104, wherein the composite has a relative density of about 0.2 to about 0.35.

110. The method of any one of claims 64 to 109, wherein the composite is isotropic.

111. The method of any one of claims 64 to 110, wherein the composite is viscoelastic.

112. The method of any one of claims 64 to 110, wherein the composite is viscoelastic-viscoplastic.

113. A method of producing a layered syntactic elastomeric composite, comprising:

producing a plurality of layers of elastomeric composite according to the method of any one of claims 64 to 112,

wherein the elastomer used in each of the layers is the same;

and wherein

each layer has a different relative density compared to the relative density of an adjacent layer,

each layer has a different average cell size compared to the average cell size of an adjacent layer, and/or

each layer comprises insoluble particles that are different, optionally having a different size, diameter, shape and/or composition, compared to the insoluble particles comprised in an adjacent layer.

114. A method of producing a layered elastomeric composite, comprising:

producing a plurality of layers of elastomeric composite according to the method of any one of claims 64 to 112,

wherein the elastomer used in each of the layers is the same;

and wherein

each layer has a different relative density compared to the relative density of an adjacent layer,

each layer has a different average cell size compared to the average cell size of an adjacent layer, and/or

each layer comprises insoluble particles that are different, optionally having a different size, diameter, shape and/or composition, compared to the insoluble particles comprised in an adjacent layer.

115. The method of claim 113 or 113, comprising:

preparing a first mixture and curing the first mixture to obtain a first layer;

preparing a second mixture, pouring the second mixture adjacent to the first layer and curing the second mixture to obtain a second layer; and

optionally preparing a third mixture, pouring the third mixture adjacent to the first or second layer, and curing the third mixture to obtain a third layer.

116. A method of preparing a syntactic cell-graded elastomer composite, comprising:

preparing a first mixture comprising an elastomer and first insoluble particles;

preparing a second mixture comprising the elastomer and second insoluble particles, the second insoluble particles having a larger size and/or diameter compared to the first insoluble particles;

optionally preparing a third mixture comprising the elastomer and third insoluble particles, the third insoluble particles having a larger size and/or diameter compared to the second insoluble particles;

optionally preparing a fourth mixture comprising the elastomer and fourth insoluble particles, the fourth insoluble particles having a larger size and/or diameter compared to the third insoluble particles;

pouring the first mixture into a cavity;

pouring the second mixture into the cavity;

optionally pouring the third mixture into the cavity;

optionally pouring the fourth mixture into the cavity;

optionally pressing down the combined mixtures;

curing the mixture to obtain the composite; and

reducing the size of the insoluble particles.

wherein the insoluble particles have at least one of compressive yield point, decomposition temperature point, melting point and density lower than at least one of compressive yield point, decomposition temperature point, melting point and density of the elastomer.

117. A method of preparing a cell-graded elastomer composite, comprising:

preparing a first mixture comprising an elastomer and first insoluble particles;

preparing a second mixture comprising the elastomer and second insoluble particles, the second insoluble particles having a larger size and/or diameter compared to the first insoluble particles;

optionally preparing a third mixture comprising the elastomer and third insoluble particles, the third insoluble particles having a larger size and/or diameter compared to the second insoluble particles;

optionally preparing a fourth mixture comprising the elastomer and fourth insoluble particles, the fourth insoluble particles having a larger size and/or diameter compared to the third insoluble particles;

pouring the first mixture into a cavity;

pouring the second mixture into the cavity;

optionally pouring the third mixture into the cavity;

optionally pouring the fourth mixture into the cavity;

optionally pressing down the combined mixtures;

curing the mixture to obtain the composite; and

reducing the size of the insoluble particles.

wherein the insoluble particles have at least one of compressive yield point, decomposition temperature point, melting point and density lower than at least one of compressive yield point, decomposition temperature point, melting point and density of the elastomer.

118. The method of any one of claims 64 to 117, wherein the composite comprises open cells.

119. The composite of any one of claims 1 to 63 or the method of any one of claims 64 to 118, wherein the insoluble particles have a compressive yield point lower than the compressive yield point of the elastomer.

120. The composite of any one of claims 1 to 63 or the method of any one of claims 64 to 118, wherein the insoluble particles have a decomposition temperature point lower than the decomposition temperature point of the elastomer.

121. The composite of any one of claims 1 to 63 or the method of any one of claims 64 to 118, wherein the insoluble particles have a melting point lower than the melting point of the elastomer.

122. The composite of any one of claims 1 to 63 or the method of any one of claims 64 to 118, wherein the insoluble particles have a density lower than the density of the elastomer.

123. The composite of any one of claims 1 to 63 or the method of any one of claims 64 to 118, wherein the composite has an open cell structure.